es0001_rev3.pdf

Workmanship Standards

Approved date:6 Aug 2012

Created by: R. Radl

Approved by: G Weaver

Doc. No.: ES0001 Rev. 3

ES0001

WORKMANSHIP STANDARD

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Table of Contents

1.0 MATERIAL STANDARDS .................................................................................. 3

2.0 CASTING STANDARDS .................................................................................... 5

3.0 ELASTOMER/RUBBER STANDARD ................................................................... 6

4.0 FIBER REINFORCED PLASTIC (FRP) ............................................................... 7

5.0 FABRICATION STANDARD .............................................................................. 7

6.0 HEAT TREATING STANDARD ......................................................................... 13

7.0 MACHINING TOLERANCE STANDARD ........................................................... 14

8.0 BLASTING/PAINTING & COATING STANDARD ............................................. 14

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1.0 MATERIAL STANDARDS

1.1 All material shall be purchased in accordance with FLSmidth (FLS)

purchase orders, drawings, and applicable material specifications.

Turn6key equipment shall meet all the requirements outlined in the FLS purchase order.

1.2 All material purchased shall meet the requirements of the applicable

material specification and shall maintain traceability back to the

original Material Test Report (MTR). All purchased material at a

minimum shall have the material type, grade and applicable heat

number permanently marked into the part (new steel bars, plates, and

shapes in accordance with ASTM A6 or other acceptable marking

specification). This marking shall be applied by the supplier of the raw

material. Material that falls outside the acceptable range or does not

have the proper marking shall be replaced or have a formal request for

deviation sent to FLS. FLS Engineering will review and determine if

this deviation is acceptable.

1.3 (When required by contract) All plate, piping, beams, or other

material that are cut into different sections shall have the applicable

material type, grade and applicable heat number transferred onto

them by stamping using low stress stamps, etching or other FLS

approved method.

1.4 Typical Materials used on FLS product are outlined below:

Ferrous Materials

FORMS GENERIC SPECIFICATION STANDARD 6,

Plate, Sheet, Bar and Structural Shapes

Mild Stl, Stl, Carbon Stl,

H.R. St!

ASTM A36

Plate, Sheet Abrasion/Impact Resistant Steel, AR Steel

***

Pipe, welded and seamless Carbon Steel Pipe ASTM A53

Seamless Pipe Carbon Steel Pipe ASTM A106 GRADE B

Structural Tubing Stl/Carbon Steel Tubing ASTM A6500 GRADE B

Alloy Mechanical Tubing Stl/Carbon Stl Tubing AISI

4140/4142

ASTM A519

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FORMS GENERIC SPECIFICATION STANDARD 6,

Mechanical Tubing Stl,

Carbon

Stl

Tubing

ASTM A513 TYPE 1 (HR)

ASTM A513 TYPE 2 (CR)

Bar, Rounds/Shafting CRS, STL AISI C61018,1020

Castings Steel ASTM A27

ASTM A148

All Alloy STL

Grade A for 2" diameter or smaller. Grade B for larger than 2" diameter.

Below 2" Could be ASTM A6500 or ASTM A6513, Verify ASTM Specification with FLS

Engineering.

Stainless Steel

FORM

GENERIC

SPECIFICATION

STANDARD

Plate, Sheet,

Bar, Shapes,

Rounds

Stainless Steel ASTM A240 TYPE 354

ASTM A276 TYPE 304

Plate, Sheet,

Bar, Shapes,

Rounds

304SS / 304LSS ASTM A240 TYPE 304/304L

Plate, Sheet,

Bar, Shapes,

Rounds

316SS / 316LSS ASTM A240 TYPE 316/316L

Non5Ferrous Materials

FORM GENERIC SPECIFICATION STANDARD

Plate, Sheet, Bar, Coil Aluminium 60616T6

Structural Shapes Aluminium

Castings Aluminium A356

Non5Metallic

Non Metallic Non

Non Metallic Non

1.5 MTR’s are required by the Purchase Order and shall become part of the final

document package as well as any dispositioned Deviation Request.

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2.0 CASTING STANDARDS

2.1 All casting chemical and mechanical test results shall conform to the

applicable material standard that was specified.

2.2 Castings shall be in a normalized and tempered condition.

2.3 All heat treatments including Post Weld Heat Treatment (PWHT) shall

be documented and reported.

2.4 All Castings require a 100% visual inspection in accordance with ASTM

A802 or MSS6SP655 using a SCRATA reference comparator.

2.5 Other Non6destructive Examination such as Magnetic Particle, Liquid

Penetrant or Ultrasonic Examination may be required.

2.6 Casting repair

2.6.1 All casting indications shall be mapped.

2.6.2 All discrepancies shall be removed until the indication has been

terminated and verified by either Magnetic Particle or Liquid

Penetrant Examination.

2.6.3 Casting indications that meet or exceed 20% of wall thickness,

1inch (25.4 mm) or 10 inches (254 mm) square shall be

considered MAJOR repairs.

2.6.4 Repairs shall be made using FLS approved welding procedures.

Note that all Major indications shall be repaired.

2.6.5 Where required by the material specification all repairs shall

receive a PWHT.

2.6.6 All repairs shall be blended to an as6cast profile.

2.6.7 10% of all repairs shall receive a Brinell hardness test. Each test

shall consist of one reading on the base (parent) material, one

reading on the Heat Affected Zone (HAZ), and one reading on

the weld itself. Hardness test shall be documented and reported.

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3.0 ELASTOMER/RUBBER STANDARD

FLSmidth shall specify in the Engineering Drawing or Purchase Order the proper elastomer/rubber compound for the application in which the coated

parts shall be used.

3.1 Drawings shall specify generic elastomer compounds (i.e. neoprene,

natural rubber, butyl, etc.). FLS Engineering shall supply applicable

compound or mechanical properties to be used if other than standard

ASTM specification.

3.2 All elastomers shall be inspected for blistering, tears, or other defects

that are deemed detrimental to the wear life of the elastomer both pre

and post cure.

3.3 A spark test shall be required to ensure there are no discontinuities in

the coated surface.

3.4 All elastomers shall have a durometer (hardness) value assigned to

them. This shall be verified using a durometer gage. The allowable

durometer range where not stated shall be +/6 5. The test results shall

be documented and made available to FLS.

3.5 Standard ASTM specifications used for testing are as follows:

• ASTM D412 6 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension

• ASTM D2240 6 Standard Test Method for Rubber Property—Durometer Hardness

• ASTM D�378 � Standard Test Methods for Rubber (Elastomeric) Conveyor Belting, Flat Type

• ASTM D624 6 Standard Test Method for Tear Strength of

Conventional Vulcanized Rubber and Thermoplastic Elastomers

• ASTM D1646 6 Standard Test Methods for Rubber—Viscosity, Stress Relaxation, and Pre6Vulcanization Characteristics

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4.0 FIBER REINFORCED PLASTIC (FRP)

FLSmidth Engineering shall specify the FRP type to be used. FLS Procurement shall reference all applicable documentation in the Purchase Order to ensure

that all requirements are met.

4.1 All FRP parts shall have a visual inspection for defects in accordance

with ASTM D2563 with acceptance criteria per Table 1 of ASTM D2563.

4.2 A Barcol hardness test shall be performed in accordance with ASTM

D2583. The test results shall be documented and made available to

FLS.

4.3 Where applicable per project specification, the following standards may

also be applied and shall be specified in the Purchase order and or ITP:

• ASTM D2584 – Standard Test Method for Ignition Loss of cured

reinforced resins (burn test).

• ASTM D638 – Standard test method for tensile properties of

plastics.

• ASTM D790 – Standard test method for flexural properties of

unreinforced and reinforced plastics and electrical insulating

materials.

• ASME RTP61 – Reinforced Thermoset Plastic corrosion6resistant

equipment.

5.0 FABRICATION STANDARD

All fabricated components made for FLS shall meet the minimum

requirements of this standard.

5.1 Weld Procedures Specifications (WPS)

5.1.1 All Welding Procedure Specifications (WPS) shall be written in

accordance with the appropriate welding specification. Unless

otherwise specified, FLS Salt Lake City uses the American

Welding Society (AWS) specification D1.1 or D1.6 as the

standard. However other standards such as ISO, EN, CSA,

CWB, or ASME may be used once approved by FLS. All suppliers

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are expected to maintain the most recent copy of the welding

standard to which they are working.

5.1.2 All WPS’s shall be submitted to FLS for review and approval

prior to start of fabrication.

5.1.3 Once a WPS has been approved by FLS it shall be followed for

all work performed on FLS product.

5.1.4 It is the supplier’s responsibility to provide FLS updated WPS’s.

5.2 Procedure Qualifications Record (PQR)

5.2.1 All WPS’s shall be qualified where required by the welding

standard.

5.2.2 All PQR’s shall be submitted to FLS for review and approval prior

to start of any fabrication.

5.2.3 Any weld process used that has not successfully been qualified

shall be rejected.

5.3 Welder Qualification Recorded

5.3.1 All welders performing work for FLS shall be qualified in

accordance with the applicable standard for the welding process

they are using.

5.3.2 Any welding performed by an unqualified welder shall be subject

to rejection by FLS.

5.4 Welding Process

5.4.1 All welding shall be done in accordance with this specification

and the applicable Welding Standard as well as the approved

WPS/PQR. All Fabrication suppliers shall be approved for work

by FLS Purchasing/Contract Fabrication Department.

5.4.2 All Filler material to be used on FLS product shall be stored,

handled and used in accordance with manufacturers

recommendations. The filler material shall be per the WPS.

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5.4.3 All flux, spatter, slag and scale shall be removed from surfaces,

welds and edges. Acceptable methods for removal are chipping,

grinding, chiselling or chemical (anti6spatter).

5.4.4 All holes, edges and corners shall be ground or deburred. All

sharp edges shall be removed by grinding. Unsightly marks or

gouges shall be blended by grinding.

5.4.5 All rust, scale and/or tint shall be removed from welding

surfaces by grinding, sanding, brushing or chemical means.

(Note: Abrasive tools used on stainless steel shall not be

contaminated by another material, likewise blast media shall be

of same type as parent material).

5.4.6 No splices are permitted in structural members unless specified

in FLS drawings or approved by FLS Engineering.

5.4.7 Weldment dimensions are finished dimensions and allowance for

shrinkage or other fabrication techniques shall be the

responsibility of the fabricator.

5.4.8 The faces of fillet welds may be slightly convex, flat or slightly

concave. (Reference Figure 1: Acceptable and Unacceptable

Weld Profiles).

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Figure 1: Acceptable and Unacceptable Weld Profiles

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5.5 Weld Repairs

All welds shall be visually inspected to ensure that workmanship meets

the requirements of the appropriate specification, drawings, PO

requirements and this standard. All repairs shall be made using an

approved weld procedure.

5.5.1 Overlap, excessive convexity or excessive reinforcement shall be

removed.

5.5.2 Excessive concavity of weld or crater, undercutting or undersize

welds shall be repaired by adding additional material.

5.5.3 Incomplete fusion, excessive porosity, slag inclusions or other

unacceptable defects shall be removed and repaired by re6

welding.

5.5.4 Cracks in either the weld or base material shall be examined by

Magnetic Particle or Liquid Penetrant Examination to assess the

severity of the crack and to ensure that the crack has been

terminated. All cracks shall be removed as well as 2” (50 mm)

of sound material on either side of the crack and repaired by re6

welding.

Note: Removal of weld metal or portions of base material may be done

by grinding, chipping, machining or gouging. Care shall be given to assure that adjacent weld or base material is not nicked or gouged.

5.6 Weld Inspection/Acceptance Criteria

5.6.1 All welds shall be Visually Inspected in accordance with the

applicable AWS (or other approved) Standard, FLS Drawings

and ITP. All Visual Inspection shall be done by a qualified

inspector as defined by AWS D1.1 section 6.1.4. See section 5.7

below for a description of Qualifications.

5.6.2 All cracks and other rejectable defects shall be repaired using

the approved welding process. All welds shall be free of slag

inclusions and porosity.

5.6.3 Welds shall exhibit no indications of overlap. Thorough fusion

shall exist between adjacent weld layers, weld metal and base

metal interface.

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5.6.4 All craters shall be filled to the full cross section of the weld.

5.6.5 For materials less than 1” thick (25 mm), undercut shall not

exceed 1/32” (1 mm), except that a maximum of 1/16” (1.5

mm) is permitted for accumulated length of 2” (50 mm) in any

12” (300 mm). For material greater than or equal to 1” (25 mm)

thick a maximum of 1/16” (1.5 mm) is permitted for any length

of the weld.

5.6.6 Fillet welds in any single continuous length shall be permitted to

under6run the nominal filet size specified by 1/16” (1.5 mm)

uncorrected, provided that the undersize portion of the weld

does not exceed 10% of the length of the weld.

5.7 Qualification of Weld Inspector 6 All Inspectors authorized to perform

inspection of welds shall meet the requirements of AWS D1.1 Section

6.1.4.

5.7.1 May be a Certified Weld inspector from AWS or equivalent such

as CWBI, CGBS, IWI B or ASNT Level II or III in VT

5.7.2 May be an individual who by training or experience or by both in

metal fabrication, inspection and testing is competent to

perform inspection of work. This will be reviewed and approved

by FLS.

5.8 Fabrication Dimensional Tolerances 6 Where dimensions are not

specified by FLS Engineering the following shall apply.

5.8.1 Non6Locating:

+/6 1/8” (3 mm) 0 to 40’ (0 to 12.2 M)

+/6 1/4” (6 MM) over 40’ (12.2 m)

5.8.2 Positioning and Locating:

Bolt Circles – Diameters Solid Flange +/6 1/32” (1 mm) 0 to 4’ (0 to 1.2 M) Rim Flange +/6 1/16” (1.5 MM) 0 to 20’ (0 to 6 M)

Bolt Spacing, Locating Chord or Mating Dimensions

+/6 1/32” (1 MM) less than 2’ (610 mm) Non6accumulative

+/6 1/16” (1.5 MM) 2’ (610 mm) & over Non6accumulative

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5.8.3 Fabrication camber or sweep & flatness

Permissible variation (in) =.013 X Length (ft) / 10

(mm) =10.8 X Length (m) / 10

5.8.4 Butt joint alignment

Offset shall not exceed 10% of the thickness of the thinner

material being joined. Maximum allowable offset shall be 1/8” (3mm).

5.8.5 Plumbness of tanks

The maximum out6of6plumbness of the top shell relative to the bottom shell shall not exceed 1/200 of the total tank height.

5.8.6 Roundness Radii measured at the 1 foot (0.3 m) mark above the

bottom corner weld shall not exceed the following:

Under 20 foot (6 m) +/61/4 inch (6 mm)

20 to 40 foot (6 to 12 m) +/61/2 inch (13 mm) 40 to 150 foot (12 to 45 m) +/63/4 inch (19 mm) 150 to 250 foot (45 to 75 m) +/61 inch (25 mm)

Over 250 foot (75 m) +/61 ¼ inch (32 mm)

5.9 Welding Symbols 6 All weld symbols shall be per either AWS A2.4 or

ISO 2553

6.0 HEAT TREATING STANDARD

6.1 Materials shall be heat treated (where required) to WPS or applicable

ASTM standard. If no procedure is stated then supplier must contact

FLS engineering for further instructions.

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7.0 MACHINING TOLERANCE STANDARD

7.1 Standard Tolerance when not called out on the FLSmidth drawings

7.1.1 Standard Surface Finish

a) Machine Surfaces 125 RMS (3 µm)

b) Threads & Thread Reliefs 63 RMS (1 µM)

c) Non6Standard Finish 250 RMS (6 µm)

d) Remove all sharp edges and burrs

7.1.2 Angles & Radius

Angle Tolerance +/6 1 Degree Fillet Radius .030 min. (1 mm)

7.1.3 Dimensional call outs

7.1.4 Undersize dimensions cannot be brought back into tolerance by

the build6up of coatings or plating.

8.0 BLASTING/PAINTING & COATING STANDARD

8.1 Uncoated machined surfaces, cast iron surfaces, shafting, mating

surfaces, threaded and bolting surfaces and flange faces, shall be cleaned, free of rust and other foreign matter, and given a

heavy coating with a solvent removable rust inhibiting compound suitable for extended storage.

8.2 All blasting, painting and coatings shall be done in accordance with

FLSmidth drawings, manufactures recommendation and/or inspection

and test plans.

8.3 Abrasive basting shall be done in accordance with either Steel

Structures Painting Counsel (SSPC) or NACE standards.

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8.3.1 White Metal Blast (SSPC 6 SP5, NACE #1)

In this method, all visible rust, mill scale, paint and

contaminants are removed, leaving the metal uniformly white or

gray in appearance. This method is to be used where maximum

performance of protective coatings is necessary due to

exceptionally severe conditions such as constant immersion in

water or liquid chemicals.

8.3.2 Commercial Blast (SSPC – SP6, NACE #3)

In this method, all oil, grease, dirt, rust scale and foreign matter

are completely removed from the surface and all rust, mill scale

and old paint are completely removed by abrasive blasting

except for slight shadows, streaks or discolorations caused by

rust stain, mill scale oxides or slight residues of paint or coating

that remain. If the surface is pitted, slight residue of rust or

paint may be found in the bottom of pits; at least two6thirds of

each square inch of surface area shall be free of all visible

residues and the remainder shall be limited to the light residues

mentioned above.

8.3.3 Brush Off Blast (SSPC – SP7, NACE #4)

In this method, all oil, grease, dirt, rust scale, loose mill scale,

loose rust and loose paint or coatings are removed completely.

Tight mill scale and tightly6adhered rust, paint and coatings are

permitted to remain. However all mill scale and rust must have

been exposed to the abrasive blast pattern sufficiently to expose

numerous flecks of the underlying metal fairly uniformly

distributed over the entire surface.

8.3.4 Near White Blast (SSPC – SP10, NACE #2)

In this method, all oil, grease, dirt, mill scale, rust, corrosion

products, oxides, paint or other foreign matter have been

completely removed from the surface by abrasive blasting,

except for very light shadows, very slight streaks or slight

discolorations caused by rust stain, mill scale oxides or slight,

tight residues of paint or coating. At least 95% of each square

inch of surface area shall be free of all visible residues, and the

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remainder shall be limited to the light discolorations mentioned

above.

8.4 All coating applications shall be done in accordance with SSPC – PA1

and the manufactures recommendations. All required criteria shall be

followed to ensure that desired results are achieved.

8.5 Prior to applying the coating all surfaces shall be blasted in accordance

with the required surface preparation and shall have achieved the

required anchor (blast) profile per the manufactures recommendations

or per FLSmidth drawing(s). Area shall be dry, free from dust, dirt,

grease, or other contaminates that could affect the performance of the

coating.

8.6 Coating should be applied in an environmentally controlled coating

booth or room where possible. If coatings are to be applied outside,

then they shall be done during the daylight hours and shall only be

done when weather is permitting. If there is a possibility of rain, fog,

mist or if relative humidity is at or above 85%, coatings shall not be

applied until such time as weather permits. Surface temperature shall

be maintained at a minimum of 5°F above the dew point to prevent

oxidation of the cleaned surface.

8.7 Large areas shall be sprayed in two directions to ensure even and

complete coating coverage.

8.8 Runs, sags, drips, skips or other surface defects are not acceptable

and shall be removed and recoated. In the event that a large area is

found to be unacceptable the paint shall be removed by blast and

recoated.

8.9 All coated surfaces shall meet the required minimum dry film thickness

(DFT). If the surface is found to not meet the required mil thickness

another layer of coating shall be applied. If the coating exceeds the

required mil thickness a deviation shall be submitted to FLS for

disposition by FLS Engineering.

8.10 Coated surfaces shall be inspected in accordance with SSPC – PA2. At

a minimum the following shall be recorded for all coated surfaces and

be submitted to FLSmidth at the completion of the coating process:

• Coating to be used

• Blast Profile

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• Dry Film Thickness (DFT) per PA2

• Visual Inspection

• Drawing used

Where required by FLSmidth purchase order the following may also be

required to be recorded

• Air Temperature

• Relative humidity

• Surface Temperature

• Dew Point

• Wet Mil Thickness (each coat)

• DFT each coat

• Adhesion Test

• Holiday Test

8.11 Hot6Dip Galvanizing shall be applied per ASTM A123 / A123M.

es0001_rev3.pdf

Documents

material standards

purchased material

raw material

applicable material

elastomerrubber standard

fabrication standard

workmanship standards

machining tolerance